U.S. patent number 6,860,911 [Application Number 10/086,902] was granted by the patent office on 2005-03-01 for synfuel composition and method of using same.
Invention is credited to Joseph W. Hundley.
United States Patent |
6,860,911 |
Hundley |
March 1, 2005 |
Synfuel composition and method of using same
Abstract
The present invention re lates to a liquid synfuel additive
composition which is used as an additive to coal fines to enhance
the complete combustion of the coal after turning it into a
synthetic fuel. The composition is a chemical change agent in that
it converts the coal/composition mix into a different material
which, when burned, results in lower noxious emissions. The
composition includes a wax, a base for ph adjustment and water.
Inventors: |
Hundley; Joseph W.
(Martinsville, VA) |
Family
ID: |
32512155 |
Appl.
No.: |
10/086,902 |
Filed: |
March 1, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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757765 |
Jan 10, 2001 |
6740133 |
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Current U.S.
Class: |
44/620; 44/280;
44/281; 44/301; 44/603; 44/628 |
Current CPC
Class: |
B01F
17/0028 (20130101); B01F 17/0042 (20130101); C10L
10/02 (20130101); C10L 5/32 (20130101); C10L
9/10 (20130101); C10L 1/328 (20130101) |
Current International
Class: |
B01F
17/00 (20060101); C10L 5/00 (20060101); C10L
10/00 (20060101); C10L 10/02 (20060101); C10L
9/10 (20060101); C10L 5/32 (20060101); C10L
9/00 (20060101); C10L 1/32 (20060101); C10L
005/00 () |
Field of
Search: |
;44/280,281,301,628,603,620 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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54048 |
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Feb 1967 |
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CN |
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1031363 |
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Mar 1989 |
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CN |
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1116650 |
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Feb 1996 |
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CN |
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1290729 |
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Apr 2001 |
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CN |
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Primary Examiner: Toomer; Cephia D.
Attorney, Agent or Firm: Hiney; James W.
Parent Case Text
BACKGROUND OF THE INVENTION
The present invention relates to a liquid synfuel additive
composition for application to materials such as coal for
facilitating more complete and efficient combustion thereof. This
application is a Continuation-In-Part of Ser. No. 09/757,765, filed
Jan. 10, 2001, now U.S. Pat. No. 6,740,133 under the same title,
"Synfuel Composition and the Method of Using Same" by the same
inventor, J. Hundley.
Claims
I claim:
1. A liquid chemical change reagent for use with solid fuels, such
as coal or wood, prior to combustion thereof, to reduce NOX and to
facilitate complete combustion consisting of: a hydrocarbon wax
which includes a fatty acid, water and a base to neutralize the
fatty acid, said neutralized fatty acid is a primary emulsifying
agent and forms an oil and water emulsion, whereby NOX are reduced
and complete combustion is facilitated.
2. The chemical change reagent as in claim 1 wherein said fatty
acid is stearic acid.
3. The chemical A change reagent as in claim 1 wherein said
hydrocarbon wax is selected from the group consisting of paraffin
wax, slack wax, microcrystalline wax, olefinic wax materials and
mixtures thereof.
4. The chemical change reagent as in claim 1 wherein said
hydrocarbon wax is paraffin wax with paraffin oil.
5. The chemical change reagent as in claim 1 and wherein the base
is ammonia or ammonia hydroxide which reacts with the fatty
acid.
6. The chemical change reagent as in claim 1 wherein the percentage
of fatty acid is 2% by weight.
7. The chemical change reagent as in claim 3 wherein said reagent
consists of 46% by weight of said paraffin wax.
8. The chemical change reagent for use with solid fuels, such as
coal or wood, prior to combustion thereof, to reduce NOX and to
facilitate complete combustion consisting of: a hydrocarbon wax
which includes a fatty acid, water and a base to neutralize the
fatty acid, said neutralized fatty acid is a primary emulsifying
agent and forms an oil and water emulsion, and titanium dioxide,
whereby NOX are reduced and complete combustion facilitated.
9. The chemical change reagent as in claim 8 wherein said titanium
dioxide is 4.5% by weight.
10. The chemical change reagent for use as a combustible fuel
additive to enhance complete combustion and/or reduce NOX and to
facilitate complete combustion consisting of the following:
11. The chemical change reagent as in claim 10 wherein said other
wax is stearic acid.
12. The chemical change reagent as in claim 10 wherein said slack
wax is paraffin wax.
13. A method of reducing NOX and facilitating complete combustion
of solid fuels such as coal and wood, said method comprising
applying a chemical change agent to said solid fuels prior to
combustion, said chemical change agent consisting of a hydrocarbon
wax, stearic acid and other fatty acids, a base for pH adjustment
which reacts with said fatty acid, and water; and burning said
solid fuels.
14. The method of claim 13 wherein said base is ammonia.
15. The method of reducing NOX and facilitating complete combustion
of solid fuels such as coal and wood, said method comprising
applying a chemical change agent to said solid fuels prior to
combustion, said chemical change agent consisting of a hydrocarbon
wax, stearic acid and other fatty acids, a base for pH adjustment
which reacts with said fatty acid, water and titanium dioxide; and
burning said solid fuels.
16. The method of claim 15 wherein said base is potassium
hydroxide.
17. The method of claim 15 wherein said base is sodium
hydroxide.
18. The method of claim 13 wherein said wax is present from 0.5% to
70% by weight.
19. A chemical change reagent for application to coal for enhancing
the combustion thereof and/or reducing NOX and facilitating
complete combustion consisting of the following composition by
weight: 0.5% to 70% of paraffin wax and stearic acid or other fatty
acid; 0.2% of a base for pH adjustment, said base reacting with
said fatty acid, and 30% to 99% water.
Description
This invention centers around a substance to convert raw coal fines
into a synthetic fuel product. This substance, classified as a
chemical change agent, contains functional groups, which are
chemically active, and combine with coal to bring about a
compositional change.
PRIOR ART
There is no existing prior art so far as the inventors hereof are
aware. There have been fatty acids used in making wax emulsions for
the purpose of sealing them against liquid water.
Paraffinic compounds are known to be water repellant and thus
paraffin is typically used as a compound of wood preservative
agents. For Example, U.S. Pat. No. 4,389,446 discloses a
composition useful as a wood preservative agent which includes an
organic solvent, solid paraffin as a water repellant agent and a
biocide.
There is a great need for additives to combustibles these days
which tend to act as chemical change agents to facilitate more
complete combustion. Accordingly, there is an ongoing need for such
chemical change agents to facilitate more complete combustion of
coal.
It is an object of this invention to provide a chemical change
agent to facilitate the complete combustion of coal, and
It is another object of this invention to provide a synfuel
additive which is environmentally acceptable and inexpensive,
and
These and other objects of this invention will become more apparent
when reference is had to the accompanying specification.
SUMMARY OF THE INVENTION
The present invention relates to an aqueous composition to be used
as a synfuel additive for combustible materials, especially
coal.
The product contemplated by this invention is a latex emulsion
comprising a paraffin wax or wax, a polyvinyl alcohol and water.
The percentage of each ingredient is as follows:
Paraffin wax or wax 22.5% Polyvinyl alcohol 3.5% Water 74.0%
Other additives can be used to improve properties including varying
percentages of polyvinyl acetate. A blend of 90% of the latex
emulsion, specified above, with 10% polyvinyl acetate produced good
burning results. Likewise, the latex emulsion by itself proved to
be a satisfactory synfuel additive. The use of the polyvinyl
alcohol, makes the emulsion.
The use of the polyvinyl agent produces a chemical change agent
which turns the composition into a synfuel. The invention
contemplates adding polyvinyl acetate to the composition to enhance
it's combustibility. It is contemplated that 10% or more may be
added to the composition. The range can be from 0 to 20%.
It is also contemplated to add a pigment composition to make the
chemical change agent black so as to blend with the coal. The use
of carbon black may interfere with the strength of the film. The
use of TiO.sub.2 or CaCO.sub.2 adds strength to the film. The use
of these white pigments makes it easy to identify the coal that has
been treated. There is an added benefit to add calcium-containing
material like Calcium Oxide or Calcium Carbonate, as these
compounds, when burned with the fuel, will react with Sulfur
Dioxide to form Calcium Sulfate.
The exact percentages of the ingredients apparently can vary as
follows:
Paraffin wax or other wax 0% to 55% Polyvinyl alcohol 0% to 50%
Further testing is required to determine if the polyvinyl alcohol
will work by itself. The Paraffin wax will not qualify as a
synthetic material unless it is a synthetic wax.
The combination of polyvinyl alcohol and wax is synthetic since the
polyvinyl alcohol is synthetic and is required to emulsify the
wax.
The best product will have a solids content of from 25% to 50% with
a 2% to 10% of the solids coming from polyvinyl alcohol and the
remainder coming from the wax. The polyvinyl acetate may be added
as needed.
The action of the moisture barrier and vapor barrier aspects of the
composition are thought to be important to the action of the
synfuel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The compositions of the invention generally comprise at least one
hydrocarbon was dispersed in an aqueous emulsion, which can form a
film on particles of coal. The emulsions used in the composition of
the present invention are preferably made using polyvinyl alcohol
as the emulsifying agent. Thus, in it broadest form, the present
invention relates to an aqueous composition comprising a
hydrocarbon wax, a polyvinyl alcohol emulsifying agent, and the
balance of water.
The aqueous composition of the present invention is designed for
use as a coating for application to materials when burned. The
purpose of using the film of the present invention is aide the
combustion of the material to which it is applied.
Typical materials to which the composition of the present invention
may be applied include materials such as coal, both bituminous and
sub bituminous as well as lignite, wood and rubber.
The aqueous film composition of the present invention may be
applied to a number of different materials. Both whole coal as well
as coal "tailings" or fines can be coated with the instant film to
facilitate combustion of the resulting material as a synfuel.
Representative non-limiting examples of the hydrocarbon waxes of
the present invention include paraffin wax, slack wax,
microcrystalline wax, olefin waxes and other, conventional, know
hydrocarbon waxes. More preferred hydrocarbon waxes are those made
up of relatively high molecular weight components since such waxes
tend to exhibit better film-forming properties. Included in the
hydrocarbon waxes are fatty acids like Oleic, Steaeric, Linoleic,
Linolenic, Palmitic, Myristic, Lauric, Capric and other fatty
acids.
The aqueous composition of the present invention comprises 5.0% to
45.0% by weight, based on the total weight of the composition, of
the hydrocarbon wax. More preferably, the aqueous composition of
the present invention comprises 10% to 35% by weight of the
hydrocarbon wax and, as a preferred ratio, the aqueous coating
composition of the invention comprises 15 to 25% by weight of the
hydrocarbon wax. Naturally, the mixtures of one or more hydrocarbon
waxes may also be employed in the aqueous composition.
In addition to water and the hydrocarbon wax, the aqueous coating
composition of the present invention comprises an emulsifying agent
such as that the aqueous composition forms an emulsion in water,
which can be applied to a coal material. The emulsifying agents
useful in the present invention are the polyvinyl alcohols. Any
form of polyvinyl alcohol may be employed in the present invention
irrespective of its degree of hydrolysis and/or degree of
polymerization. However, the degree of polymerization and degree of
hydrolysis of the polyvinyl alcohol may have an impact on the
strength of the film, which is formed from the aqueous coating
composition of the present invention. The specific polyvinyl
alcohol which is selected to be used in the present invention will
be that which demonstrates the best properties in terms of
combustion.
The polyvinyl alcohol emulsifying agent is employed in an amount of
1.0% to 10.0% by weight, based on the total weight of the aqueous
coating composition. More preferably, the polyvinyl emulsifier
comprises 2 to 5% by weight of the composition. Naturally, mixtures
or two or more polyvinyl alcohols having differing degrees of
hydrolysis and/or polymerization may be employed in the aqueous
synfuel composition of the present invention.
The composition of the present invention may also optionally
include up to 1.0% by weight of a biocide, based on the total
weight of the composition. Such biocides are known in the art and
include pesticides and other materials designed to prevent the
growth of organisms in the aqueous coating composition during
storage and use. The biocide will typically be employed in an
amount sufficient to prevent the growth of living organisms in the
aqueous coating composition during storage. Such amounts do not
usually exceed 1.0% by weight and, more preferably, only up to 0.5%
by weight of the biocide is employed. Most preferably, the biocide
comprises up to 0.105 by weight of the aqueous synfuel
composition.
In addition, the synfuel composition of the invention may
optionally contain one or more filler materials. Any conventional
filler material may be used for this purpose such as oxygen
containing compounds like sugar, acedic acid and salts of acedic
acid and other oxygen containing compounds may be added to improve
combustion. Calcium Oxide. Calcium Carbonate and Lime may be added
to the emulsion in order to add solids as well as to reduce Sulfur
Dioxide emissions. Calcium compounds may be 0% to 61% of the
formula.
The synfuel composition of the invention may be made by mixing the
ingredients using a conventional mixing apparatus. If a prolonged
storage period is anticipated, it is preferred to run the
composition through a homogenizer before putting it in a storage
container. The composition is storage stable for prolonged periods
of six months or more. The addition of a biocide prevents the
growth of undesirable organisms.
The synfuel: Composition of the present invention can be applied in
any conventional manner. For example, the composition my be applied
using spray guns immersion, etc.
The instant invention also meets all the Federal Air Quality
Regulations in 40 C. F. R. This is very significant since
conventional, commercially available synfuels, do not, in a lot of
cases, meet the Federal Standards, as they contain hazardous
components and/or volatile organic compounds. Hence, the instant
invention is environmentally friendly. The addition of polyvinyl
acetate to the basic composition enhances it burning ability when
used with coal.
In addition to being non-toxic and containing no volatile organic
compounds, the present invention does not leave any residue
necessitating clean up after combustion. In fact, it facilitates a
more complete combustion of the coal and hardly leaves any residue.
The addition of Calcium compounds also will reduce Sulfur Dioxide
emissions.
FIG. 1 is a graph of the chemical changes in weight combination
contrasted with the synfuel 20.degree. Syntex LD.
FIG. 2 is a graph of the chemical changes in weight of the raw coal
fines and the chemical change agent 0.20% Syntex LD.
FIG. 3 is a graph of the chemical change in weight of the feedstock
coal fines and the chemical change agent 0.20% Syntex LD.
FIG. 4 is a graph of the chemical change in weight of the synfuel
0.25% Syntex LD and the weight combination 25% Syntex LD.
FIG. 5 is a graph showing the comparison between CCA spectra and
the Synthetic fuel product.
FIG. 6 is a graph showing the comparison between the CCA spectra
and the Raw coal fines.
Tests on the new synfuel additive known as Syntex with High Volume
Coal Fines
Basically the new substance which forms the core of this invention
converts raw coal fines into a synthetic fuel product. The
substance, classified as a chemical change agent, contains
functional groups, which are chemically active, and combine with
coal to bring about a compositional change. The object of the tests
was to determine whether or not the chemical change agent provided
would bring about sufficient chemical reactions when combined with
the feedstock coal fines to produce a synthetic fuel product.
Raw coal fines are combined with the chemical change agent. The two
substances were then mixed to insure maximum contact to allow a
chemical reaction to occur. The mixture was then compressed to form
the synthetic fuel product. These distinctive conditions were
simulated during the test to effectively recreate those found
within a synthetic fuel plant.
The chemical combinations of the mixture can produce a synthetic
fuel source with a decidedly different chemical composition than
that of a physical mixture of the coal and agent. The industry
standard is a minimum of 15% chemical change.
The two mixture ingredients were separately analyzed as was the
mixture product using Fourier Transform Infrared spectroscopy in
order to confirm or disprove an actual chemical change within the
synthetic fuel product.
Fourier Transform Infrared spectroscopy allows one to observe the
chemical structures of materials. In this case, the analysis was
used to search for a difference in spectra among the samples
tested. Differences in the spectra of the material indicates a
chemical change among the materials. These spectral changes can
range from differences in intensify at equivalent frequencies to
different peak structures at equivalent frequencies.
The analysis spectra displayed an obvious and measurable chemical
change between the synthetic fuel product and the raw coal fines.
These measurable spectra differences indicate that the synthetic
fuel is a product of intricate chemical changes and not just a
physical combination of coal and the chemical change agent.
Two chemical change agents were used in the test. The first was
Syntex-LD and the second was Syntex-MD. The raw coal sample was
meticulously mixed and riffed to garner a smaller sample for
analysis. The raw coal was reduced in particle size using a mortar
and pestle through a sixty mesh screen. The grinding process was
performed at a minimal pace and care was taken to clean all
instruments in order to avoid a cross-contamination of samples. The
same process was used on the synthetic fuel mixture.
During the test, the raw coal, chemical change agent and synthetic
fuel spectra were obtained with a Perkin Elmer Spectrum One FTIR
spectrometer. Thirty-two scans of each sample comprised an average
to obtain final spectra listed below.
Fourier Transform Infrared Spectroscopy is useful for determining
chemical bonds within substances. Alterations in the spectra of raw
coal and the synthetic fuel indicate a change in the chemical bonds
at these wavelengths. Thus, a greater or lesser number of certain
bonds at a wavelength will lead to a change in the spectra
involved. The bonds most often seen pertaining to raw coal and the
synthetic fuel product are:
1. Carbon-carbon bonds. Basic organic molecules are constructed of
carbon--carbon bonds. These bonds may be either aromatic or
aliphatic. Aromatic carbon atoms are joined in a ring structure and
involve double bonds among the carbon bonds. The infrared area of
interest for these bonds is around 1500-1650 wave numbers. It
should be noted that most of the bond stretching occurs in the
range of 1600-1650 wave numbers. Any change in intensity of two
spectra or peak structure in this area would indicate a definite
chemical difference between two substances. Thus, if the synthetic
fuel product displays a greater or lesser intensity in this range
than the raw coal a chemical change has occurred. Peak structure
differences in this range would indicate a chemical change.
2. Carbon-Oxygen bonds. These adsorb infrared light from 1050-1250
wave numbers. The actual range of adsorption will vary depending
upon whether or not it is attached to an aliphatic or aromatic
carbon base. Any change in intensity of two spectra or peak spectra
in this area would Indicate a chemical difference between two
substances.
3. Carbon-Hydrogen bonds. These bonds are prominent in aliphatic
carbon structures with peak adsorption of infrared light at around
1360 and 1430-1470 wave numbers. In aromatic carbons the
carbon-hydrogen bonds adsorb infrared light from about 650-925 wave
numbers.
Fourier Transform Infrared Spectroscopy Results
There are comparisons of raw coal fines, synthetic fuel product and
the chemical change agent on the graphs shown as FIGS. 1 and 2. The
synthetic fuel contained 0.20% wt. of the agent and 99.80% of raw
coal. In order to construct a weight combination spectra the agent
spectra was multiplied by 0.0020 and the raw coal spectra was
multiplied by 0.9980. These two spectra were then added together to
form the Weight Combination spectra. This addition accounts for the
percentage of agent and raw coal within the sample itself.
Thus, a difference in the weight combination spectra and the
spectra of the synthetic fuel product would indicate a difference
in chemical bonds associated with each spectra. Therefore, a change
in the weight combination spectra as compared to the synthetic fuel
spectra would serve as evidence that an actual chemical change has
occurred in the formation of the synthetic fuel.
In this particular analyzation, the synthetic fuel spectra is
significantly and measurable different from the spectra of the
weight combination spectra using the prescribed agent. The
calculated mathematical difference between the weight combination
spectra and that of the synfuel spectra totaled a net 23% change.
This difference confirms the claim the the synthetic fuel product
is the production of chemical changes and not merely a physical
mixture.
FIGS. 1 and 2 show the differences between the raw coal, the agent
and the two mixtures, Syntex-LD and Syntex-MD. The LD and MD stand
for low density and medium density, terms used to describe
coal.
The results showed spectral changes and include.
1. An increase in absorbance of the doublet peak at around 1050
wave numbers. This area is associated with carbon-oxygen bonds. The
increase of the synthetic fuel's absorbance in this area indicates
a differing type of bonding than that of a physical mixture.
2. An increase in absorbance at 1600 wave numbers which is
associated with aromatic carbon--carbon bonds. This indicates that
the synthetic product has more aromatic carbon--carbon bonds than a
physical mixture would have.
3. An increase in absorbance at 2900 wave numbers. This is an area
of absorbance associated with carbon-hydrogen bonds. The synthetic
fuel product displays a larger number of these bonds than those
that would be found in a physical mixture.
4. An increase in absorbance at 1440 wave numbers. This is an area
of absorbance associated with carbon-hydrogen bonds as well. The
synthetic fuel product displays a larger number of these bonds than
those that would be found in a physical mixture.
In conclusion the analysis proved the chemical changes occur when
the chemical change agent of this invention, either Syntex-LD or
Syntex-MD is combined with raw coal fines to create a synthetic
fuel product.
Tests on the chemical change Agent know as Syntex with Low Volume
Coal Fines
The same tests were run and the results of the Fourier Transform
Infrared Spectroscopy are as follows:
There are comparisons of the raw coal fines, synthetic fuel product
and the agent on the graphs shown as FIGS. 3 and 4. The synthetic
fuel contained a 0.25% wt of agent and 99.75% wt of raw coal. In
order to contstruct a weight combination spectra the agent spectra
was multiplied by 0.0025 and the raw coal spectra was multiplied by
0.9975. These two spectra were then added together to form the
Weight Combination spectra. This addition accounts for the
percentage of agent and raw coal within the sample itself.
Thus, a difference in the weight combination spectra and spectra
associated with the synthetic fuel product would indicate a
difference in chemical bonds associated with each spectra. In this
analyzation, the synthetic fuel spectra is significantly and
measurable different from the spectra of the weight combination
spectra using the prescribed agent. The calculated mathematical
difference between the weight combination spectra and that of the
synfuel spectra total a net 19% change. This difference confirms
the claim that the synthetic fuel product is the production of
chemical changes and not a mere physical mixture.
The spectral changes that point to the chemical reactions and
change include:
1. An increase in absorbance of the doublet peak at around 1050
wave numbers. This area is associated with carbon-oxygen bonds.
2. An increase in absorbance at 1600 wave numbers. This area is
associated with aromatic carbon--carbon bonds.
3. An increase in absorbance at 2900 wave numbers which is
associated with carbon-hydrogen bonds. The number of bonds is
larger than in a mere mixture.
4. An increase in absorbance at 1440 wave numbers which is
associated with carbon-hydrogen bonds as well.
The conclusion is that again with low density coal, several
chemical changes occurred when the agent was combined with the
coal. The mixture is another entity entirely when compared with the
raw coal and agent in physical combination.
The samples are as follows:
Syntex LD 0.20% 21% Syntex LD 0.20% 27% Syntex LD 0.20% 15% Syntex
LD 0.20% 13%
The most successful formula contains paraffin wax, paraffin oil,
hydrocarbon wax in the form of stearic acid, titanium dioxide,
water and aqua ammonia. The fatty acid reacted with ammonia also
acts as an emulsifying agent. The reaction is as follows ammonium
stearate is used in this example but other fatty acids and bases
may be used. ##EQU1##
This reaction results in changing the coal in a number of
measurable ways: 1. First, it shifts the Thermo-gravimetric
analysis (TGA) to the right. The TGA test measures the temperature
and rate at which pyrolysis products evolve A change in TGA of 7%
or more indicates significant chemical change has occurred. Tests
in a laboratory report a 28% change in peak area on a TGA test.
Further tests also report a high TGA with 14.6% chance in peak
area. This is an extremely high chemical change agent that they
have tested at 0.2% application rate. 2. Second, ammonia released
from this reaction reacts with aldehydes to produce amines. 3.
Third, excess ammonia not reacted with aldehydes and other
compounds, is available to be burned with the coal. In the
combustion of coal, it has been found that ammonia will reduce
No.sub.x formation. It has also been found that if NO.sub.x are
reduced, then sulfuric acid formation is reduced.
Fourier Transform Infrared Spectroscopy allows for measurement of
chemical change. Tests run by three independent laboratories
confirm significant chemical change even at 0.2% application rate.
Lab tests show a 35% change on test samples. In refining and
improving of the fatty acid product, the inventor has understood
the role of excess ions of potassium, sodium and even ammonia on
the reactions that take place between the coal and chemical change
agent. Excess ions mentioned above act as water softeners and,
thus, slow down or stop the exchange reaction. This is the reason
one gets lower readings on FTIR tests. One test uses potassium
bromide to mix with the coal and chemical change agent. The tests
to date have been made with the following formula:
Slack wax (Paraffin wax with 11% Paraffin oil) 46.3% Other wax
(Stearic acid) 2.0% Ammonia (for ph adjustment) AR 0.2% Titanium
Dioxide 4.5% Water 47.0%
Titanium is added to control viscosity and to help the product to
be seen after it is applied to the coal. The following range of
combinations are claimed.
Wax (Paraffin wax, slack wax, Alfa Olefins, Fatty Acids) 1/2% to
70% Base for ph adjustment (Ammonium hydroxide, Potassium 0.2%
hydroxide Sodium hydroxide) as needed. Water 30%-99%
The invention of this application centers around a substance to
convert raw coal fines into a synthetic fuel product. This
substance, classified as a chemical change agent, contains
functional groups which are chemically active and combine with coal
to bring about a compositional change.
The process involves combining raw coal fines with chemical change
agents (CCAs). The two substances, the CCA and the raw coal, are
then mixed to insure maximum contact to allow a chemical reaction
to occur. The CCA and the raw coal mixture is then compressed to
form the finished synthetic fuel product. These distinctive
conditions were simulated by testing to effectively recreate those
found within a synthetic fuel plant.
The chemical combinations of the CCA and raw coal fines can produce
a synthetic fuel source with a decidedly different chemical
composition than that of a physical mixture of the constituent coal
and CCA.
Fourier Transform Infrared spectroscopy was used to analyze to
confirm An actual chemical change within the synthetic fuel
product. The spectroscopy process allows one to observe the
chemical structures of materials. In this case, the analysis was
used to search for a difference in spectra among the CCA raw coal,
and synthetic fuel samples. Differences in the spectra of the
materials would indicate a chemical change among the materials.
These spectral changes could range from differences in intensity at
equivalent frequencies to different peak structures at equivalent
frequencies.
The analysis spectra displayed an obvious and measureable chemical
change between the synthetic fuel product and the raw coal fines.
These measureable spectra differences indicate that the synthetic
fuel is a product of intricate chemical changes, and not just a
physical combination of raw coal and CCA.
The CCA used in the test was white in color at room temperature. It
is more viscous than water and it was a chemically reactive organic
substance. The synthetic fuel product was created in accordance
with conditions similar to those found within a synthetic fuel
plant. The dosage was 0.20% by weight. This was accomplished by
applying the appropriate amount of CCA to a defined amount of
feedstock coal fines.
The raw coal sample was mixed and riffled to garner a small example
for analysis representative of a field sample. The raw coal was
then reduced in size using a mortar and pestle to pass through a
sixty mesh screen. The same process was performed on the synthetic
fuel product.
Fourier Transform Infrared Spectroscopy is a test that outlines the
certain types of chemical bonds/structures that exist with a
certain substance. It works on the premise that differing chemical
structures/bonds will adsorb different levels of infrared energy or
frequencies. In this way, spectral differences between the
absorption of raw coal and that of the synthetic fuel product would
indicate differences in amounts kinds of chemical bonds within a
structure. These differences would indicate a definite deviation in
the chemical composition of the synthetic fuel product from that of
the raw coal fines.
The raw coal, synthetic fuel and CCA spectra were obtained with a
Perkin Elmer Spectrum One FTIR spectrometer from 0.1 grams of each
sample placed in a sample Holder. Thirty two scans of each sample
comprised an average to obtain final spectra Described herein. The
instrument was set at 4 wave numbers and covered a frequency Range
of from 635 to 4000 wave numbers. The greater or lesser number of
certain Bonds at a wavelength will lead to a change in the spectra
involved. Typical of the Bonds pertaining to raw coal and synthetic
fuel products are as follows:
Carbon--Carbon Bonds
Basic organic molecules are constructed of carbon--carbon bonds.
These bonds may be either aromatic or aliphatic. Aromatic carbon
atoms are joined in a ring structure and involve double bonds among
the carbon bonds. The infrared range of interest for these bonds is
around 1500-1650 wave numbers. It should be noted that most of the
double bond stretching occurs in the range of 1600-1650 wave
numbers any change in the intensity of two spectra or peak spectra
in this area would indicate a definite chemical difference between
the two substances. Thus, if the synthetic fuel product displays a
greater or lesser intensity in this range than the raw coal a
chemical change has occurred. Also, peak structure differences in
this range would indicate a chemical chance.
Carbon-Oxygen Bonds
Carbon-Oxygen bonds adsorb infrared light from 1050-1250 wave
numbers. The actual range of absorption will vary depending upon
whether or not it is attached to an aliphatic or aromatic carbon
base.
Any change in intensity of two spectra or peak structure in this
area indicates a definite chemical difference between the two
substances. Thus if the synthetic fuel product displays a greater
or lesser intensity in this range than the raw coal a chemical
change has occurred. Also, peak structure differences in this range
would indicate a chemical change.
Carbon-Hydrogen Bonds
These bonds are prominent in aliphatic carbon structures with peak
absorption infrared light at around 1360 and 1430-1470 wave
numbers. In aromatic carbons, the carbon-hydrogen bonds absorb
infrared light from about 650-925 wave numbers.
Any change in intensity of two spectra or peak structure in this
area would indicate a definite chemical difference between two
substances. Thus, if the synthetic fuel product displays a greater
or lesser intensity in this range than the raw coal a chemical
change has occurred. Also, peak structure differences in this range
would indicate a chemical change.
The results of the spectroscopy analysis is shown in FIGS. 5 and 6.
There, the synthetic fuel contained 20% wt. of CCA and 99.80% wt.
of raw coal. In order to contstruct a weight combination spectra
the CCA spectra was multiplied by 0.0020 and The raw coal spectra
was multiplied by 0.9980. These two spectra were then added
together to form the Weight Combination spectra. This addition
accounts for the percentage of CCA and raw coal within the sample
itself.
Thus, a difference in the weight combination spectra and the
spectra of the synthetic fuel product indicates a difference in
chemical bonds associated with each spectra. Therefore, a change in
the weight combination spectra as compared to the synthetic fuel
spectra would serve as evidence that an actual chemical change has
occurred in the formation of the synthetic fuel (the weight
combination spectra illustrates what would simply be a physical
combination of raw coal and CCA.
In this particular analyzation, the synthetic fuel spectra is
significantly and measurably different from the spectra of the
weight combination spectra using the prescribed CCA. The calculated
mathematical difference between the weight combination spectra and
that of the synfuel spectra totaled a net 30% change. This
difference confirms the claim that the synthetic fuel product is
the production of chemical change(s) and not merely a physical
mixture.
Spectral changes that point to chemical reactions and change
include: 1. An increase in absorbance of the doublet peak at around
1050 wave numbers, this area is associated with carbon-oxygen
bonds. The increase in the synthetic fuel's absorbance in this area
indicates a differing type of bonding than that of a physical
mixture. (weight combination). 2. An increase in absorbance at 1600
wave numbers. This area is associated with aromatic carbon--carbon
bonds. This indicates that the synthetic product has more aromatic
carbon--carbon bonds than a physical mixture would have. 3. An
increase in absorbance at 2900 wave numbers. This area is
associated with an absorbance associated with carbon-hydrogen
bonds. The synthetic fuel product displays a larger number of these
bonds than those that would be found in a physical mixture. 4. An
increase in aborbance at 1440 wave numbers. This is an area of
absorbance associated with carbon-hydrogen bonds as well. The
synthetic fuel product displays a larger number of these bonds than
those that would be found in a physical mixture.
The Fourier Transform Infrared Spectroscopy analysis of raw coal
fines, synthetic fuel product and chemical change proves that
several significant chemical changes occurred when raw coal fines
were combined with the chemical change agent to create a synthetic
fuel product. The synthetic fuel product is another entity entirely
when compared with the raw coal fines and the physical combinations
of the raw coal fines with the chemical change agent.
Further tests were conducted using the FTIR analysis,
thermo-gravimetric analysis, (TGA ?), ASTM proximate analysis, and
heating value determination. The TGA analysis indicated that a peak
pyrolysis rates of mass loss are significantly different (26.4%)
for the fuel product and simple mixtures of the ingredients. This
is evidence of significant chemical changes in the fuel product.
Good correlation between the levels of ash and sulfur for the feed
and product obtained from proximate analysis results, suggests that
no significant processing or sampling errors likely occurred with
the collection of the samples. Further testing showed that an
average difference in measured peak areas (as shown in FIGS. 5 and
6) using FTIR of 16% provides evidence of overall significant
change in chemical composition between parent materials and fuel
product. The TGA results indicate that peak pyrolysis rates of mass
loss are significantly different (36.6%) for the fuel product and
the simple mixture of parent ingredients. Further proximate
analysis results show that the difference in fixed carbon and
volatiles contents between the fuel product and simple ingredients
mixture (1.41%) are significantly different.
Having described the preferred embodiments of the invention, it
will be obvious to those or ordinary skill in the art that many
modifications and chances can be made without departing from the
scope of the appended claims.
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